Railroad flangeway filler and method

ABSTRACT

A railroad flangeway filler for a freight railroad and grade crossing comprises a section of foamed polyurethane inserted into a gap in the freight railroad and grade crossing. Preferably, the filler design has a substantially planar uppermost surface and a hard urethane base. A method for making such flangeway fillers is also disclosed.

CROSS REFERENCE TO RELATED APPLICATION(S)

This application is a perfection of U.S. Provisional Ser. No. 62/722,313, filed on Aug. 24, 2018, the disclosure of which is fully incorporated herein.

BACKGROUND OF THE INVENTION

This invention relates to railway or railroad crossing points, for pedestrian and/or vehicular traffic. More particularly, it relates to an improved means (design, material and method) for rendering the railroad flangeways safer . . . by reducing or completely eliminating the gap(s) directly next to the rail at such crossing points. With the elimination of that gap, such crossing points are rendered safer (i.e., with less tripping hazards/possibilities) especially for bicyclists, individuals who are wheelchair bound and/or pedestrians. The aspects of this invention are most suitable for railroad tracks on which trains travel at 25 mph or above.

It has been a goal of railroad crossings constructed in the past to provide a durable, inexpensive and easy-to-install vehicular supporting deck for a railroad grade crossing that provides a smooth transgression of a vehicle along a roadway surface which intersects with a railroad track. An example of such crossing is set forth in Szarka U.S. Pat. Nos. 3,955,761 and 3,863,840. A further goal of prior art railroad crossings is to provide a level surface for pedestrian and small wheeled vehicular traffic which will allow safe and smooth transgression by pedestrians and vehicles in crossing a railroad crossing.

One of the major problems in any railroad crossing is the necessity of a space or flangeway opening which is left in every crossing for allowing a railroad wheel to pass through the crossing without incident. The necessity of the existence of the flangeway openings in railroad crossings creates several disadvantages in the construction of railroad crossings and in addition, creates bumpy road conditions for pedestrians and vehicular traffic crossing the intersection. For instance, the empty space may allow the panels used in constructing these crossings to shift. This shifting of the panels creates a further bumpy surface and is undesirable. In addition, these flangeway openings create uneven surfaces for bicycles and pedestrian traffic.

Past compositions have failed in solving these problems in that the compositions have not been durable enough to be used in these crossings. They have not been structurally sound enough to prevent the problems illustrated above or they have been too expensive to be justified for use in railroad crossings, and in addition have created time-consuming applications in railroad crossings.

Flangeway filler materials used in the past include a cork composition, which is expensive and is also hard to apply in the field. Other materials include tar-like materials which do not have the structural integrity or resiliency that prove advantageous for a flangeway filler composition. In addition, compositions have been used which rapidly deteriorate when used in the rugged environment of a railroad crossing. These past compositions deteriorate leaving gaps or may pull out of the flangeway opening, both of which are undesirable characteristics.

It is a general object of the present invention to produce an elastomer composition that is particularly suited for use in flangeway openings in a railroad crossing.

It is the more specific object of the present invention to produce an elastomer composition that is durable, resilient, adhesive, and will retain its structural integrity.

It is a further object of the present invention to provide a simple process for making an elastomer composition in the field, which is suitable for use in any type railroad crossing of the highest specifications.

A further object of the present invention is to provide an elastomer composition which is durable enough to withstand continued depressions by railroad wheels passing over it and be resilient enough to bounce back from these depressions and in addition provide a material which provides a safe and smooth surface for vehicular, pedestrian, and small wheeled vehicular traffic (bicycles, etc.).

It is a further object of the present invention to provide an inexpensive, easy to apply, and superior quality elastomer composition that will meet or exceed the most demanding specifications of even the most demanding installers of railroad crossings.

It is a further object of the present invention to provide an elastomer composition which retains its structural integrity even without the benefit of the original molding walls and which will not disintegrate upon removal of the walls in which it was molded or under other conditions encountered in a railroad crossing application.

SUMMARY OF THE INVENTION

This invention addresses a railroad flangeway filler strip for various known configurations of railway crossing points as well as embedded systems that run parallel to roadways, such as streetcar systems. In particular, this invention provides for safer crossings of: typical freight railroads and grade crossings (as per FIG. 1); crossings which employ a pre-existing embedded track (FIGS. 2A through C); and/or for sections of new embedded track (per FIG. 3). It consists of a specially shaped foam urethane insert that has an uppermost contacting surface. For the pre-existing track, that upper surface is supplemented with a harder urethane base (or underlayment). The latter combination may physically attach to its adjacent track components through one or more mounting holes (or apertures) that are preferably angled to some extent. For typical freight railroad grade crossings, the aforementioned polyurethane design is meant to fit between sections of rubber bonded to steel (or a section of steel backing).

BRIEF DESCRIPTION OF DRAWINGS

Further features, objectives and advantages of this invention will become clearer with the following Detailed Description made with reference to the accompanying drawings in which:

FIG. 1 is a side sectional view of one embodiment of this invention as installed on a representative freight railroad and grade crossing;

FIG. 2A is a top perspective view of a section of flangeway filler strip as would be suitable for installation on pre-existing embedded track;

FIG. 2B is an axial sectional view of the urethane filler strip taken along lines B-B in FIG. 2A;

FIG. 2C is a longitudinal sectional view of the same representative filler strip taken along lines C-C in FIG. 2A; and

FIG. 3 is a side sectional view of another embodiment of this invention as would be installed on new, embedded track, between the rail proper and its adjoining section(s) of flangeway supports.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Material/design combination that allows for the flangeway to be filled on railroad tracks where speeds are 25 mph and above.

The flangeway filler

eliminates the gap next to the rail, thereby eliminating the hazard the gap presents to bicyclists, people in wheelchairs, and pedestrians.

The material selection is FOAMED URETHANE. One particular example uses a material made by Pleiger Plastics Company under the brand PT-13.

Because railroad tracks are built in so many ways, there is not one shape (design) that fits all applications. FIG. 1 is for freight railroads and grade crossings. Particularly therein, FIG. 1 shows a cross-sectional view of a standard freight railroad crossing, generally 10, in which there is a main steel backing element 12 having a vertical component 14 and a horizontal component 16 that meets in one corner 18. A first rubber component 20 bonds to the vertical component side 14 of steel backing element 12 though it is to be understood that at least one uppermost tip 22 of rubber component 20 at least partially overlaps the upper edge U to vertical component 14 of steel backing element 12. At that connection, there is most commonly a rubber BONDED to steel element.

At a lower end L of first rubber component 20, there is a downward, inward bevel 24 that leads to a lower rubber component extension 26 into the corner 18 of freight railroad crossing 10. A second rubber component 30 is found furthest from vertical component 14. In many instances, second rubber component 30 includes an arched top surface 32. At the lowermost edge 34 of second rubber component 30, there is an upward bevel 36 that points towards vertical component 14 of the steel backing element 12. The two parts of rubber components 20 and 30 create a natural gap G in materials that the present invention addresses. That gap G is a tripping point unless filled in per the present invention.

This invention provides a foamed urethane insert, generally 40, for fitting into gap G of freight railroad crossing 10. Insert 40 has a top surface 42 that runs substantially parallel with the uppermost tip 22 of first rubber component 20, that uppermost tip completely covering upper edge U of vertical component 14.

The lowermost region 44 of urethane insert 40 is purposefully Y-shaped having a left leg 46 that fits under and into the upward bevel 36 of second rubber component 30 while its sister (or right) leg 48 fits into the inward bevel 24 of first rubber component 20, adjacent lower rubber component extension 26. At the intersection of left leg 36 and right leg 48 of urethane insert 40, there is provided a triangularly-shaped air gap 50 directly above horizontal component 16 of the steel backing element 12. This air gap 50 provides room for compression as well as providing a shape conducive to faster rebound.

FIGS. 2A through C are various views of a second embodiment of urethane insert per the present invention this being one for a section of pre-existing embedded track. Particularly, FIG. 2A is a top perspective view of insert 140, FIG. 2B is an axial sectional view taken along lines B-B of FIG. 2A and FIG. 2C is a longitudinal sectional view of the same insert 140 taken along lines C-C of FIG. 2A. For this embodiment, it is noted that an elongated section of urethane insert 140 has a flat upper surface 142 and a lower surface 144 that is further connected (preferably by bonding) to an underlying hard urethane base 150. At least one side edge, or lower corner 152 to insert 140 is purposefully curved to conform to existing flangeway shapes present in embedded track systems. A lower sidewall 146 of insert 140 may further slope downwardly into lower corner edge 152 of hard urethane base 150 for better fastening strength to underlying surfaces.

As the foregoing embodiment is a preferred insert for embedded track applications, it is preferred that such inserts be pre-made with a mounting aperture or angled hole 160 in the various views at FIG. 2. Preferably, this hole 160 extends into the flat upper surface 142 of insert 140 and angles downward towards the lower corner 152 of the underlying hard urethane base 150 as well. Such an angled attachment mechanism provides greater securement of the insert to an underlying concrete base (not shown) for which the present invention is designed to minimize or completely eliminate unnecessary gaps between the upper surfaces of same.

FIG. 3 is for new embedded track comprised of a rail element R and a surrounding framework which, in this representative view, includes a left side metal wedge frame LW and a right side wedge frame RW with an added flangeway support FS to the right of wedge frame RW in this view. Flangeway support extends all the way down to the elongated base RB of rail element R with the entirety of this assembly fitting into an aperture A within the ground G (defined by the silhouetted circular surround in FIG. 3).

In most arrangements of today's flangeway supports, there is still left behind a defined flangeway gap FG, nearest the top element of rail R that causes the tripping and other problems that this invention was designed to fully address. Particularly, the third hook-shaped variation of foamed urethane insert 200 is meant to fit fully inside flangeway gap FG thereby reducing tripping and other traffic-related concerns. As shown, urethane insert 200 includes a main body element 202 with a top surface 204 that runs parallel or more preferably completely flush with the top to rail R and its adjoining uppermost surface US to flangeway support FS. So as to better fit within a upper recess of flangeway support FS, the urethane insert 200 further includes a downward extension 206, and a lateral ledge 208 before forming a hook leg 210 extending back upwardly behind a left most clip LC to flangeway support FS. This combination of extensions, ledges and hook legs better secures the urethane insert 200 in and about the flangeway support proper so as to not be easily removed therefrom after its initial installation.

The use of this material in the present invention provides for an advantageous cost while retaining superior workability and durability requirements when the material is put to its final use as a flangeway filler or flangeway opening filler composition.

The polyurethane resin is of the moisture curing polyurethane binder type. It is most useful in producing a resilient, yet durable and fast setting compound that will retain its molded shape without the benefit of molding walls per se.

The present invention also relates to an article of manufacture prepared by employing the compound produced in accordance with the steps disclosed above. More specifically, a flangeway space filler is provided which is manufactured by employing the composition prepared in accordance with the steps disclosed above. In addition, provided for is a method of preparation of a sealed flangeway opening in a railroad crossing by employing a composition prepared in accordance with the steps set forth herein.

The compositions of the present invention are particularly suited for use in railroad crossings where flangeway openings, i.e., the spaces between the railroad track and roadway crossing panels, create an undesirable rough crossing point. The composition designed as such must be resilient for allowing railroad wheels to indent the material while they pass over it, but preferably bounces back to its original shape such that the opening will be level for the smooth use by vehicular (including wheelchair), bicycle and/or pedestrian traffic. In addition, the compound must be durable enough to withstand the brutal conditions encountered at a railroad crossing. While used as a filling compound for flangeway openings, the urethane compound also acts to check any movement by the crossing panels toward the railroad track which movements are also undesirable.

A method for making a flangeway filler for a freight railroad and grade crossing is also disclosed. It comprises: (a) forming molded foam urethane inserts in a plurality of sizes and cross-sectional shapes, (b) measuring the freight railroad and grade crossing for a width and length of molded foam urethane insert needed; (c) determining cross-sectional shape needed for inserting into the freight railroad and grade crossing; (d) cutting the molded foam urethane insert having the proper cross-sectional shape for inserting into the freight railroad and grade crossing, and (e) anchoring the cut, molded foam urethane insert into the freight railroad and grade crossing to make the flangeway filler thereby.

Preferably, that method, prior to step (e), further includes: forming a base for the flangeway filler, said base being made from steel and then coated with hard urethane prior to inserting into the freight railroad and grade crossing. Prior to step (b) above, the method preferably includes; storing the various plurality of sizes and cross-sectional shapes of molded foam urethane inserts in elongated lengths. Alternately, they may be made and stored in various sizes and cross-sectional shapes onto spools.

The strips of molded foam urethane can either be made with a plurality of spaced apart mounting holes or have such holes added after manufacture. That would include drilling a plurality of spaced apart mounting holes into the cut molded foam urethane inserts before securing the molded foam urethane inserts into the freight railroad and grade crossing through one or more of the plurality of spaced apart, drilled mounting holes.

The invention set forth above has been described in an illustrative manner, and it is to be understood that the terminology used is intended to be words of description rather than limitation. Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is therefore, to be understood that within the scope of the appended claims, the invention may be practiced other than as specifically described. 

What is claimed is:
 1. A railroad flangeway filler design for a freight railroad and grade crossing, said filler design consisting essentially of a polyurethane insert adjacent a rubber component having a steel backing.
 2. The flangeway filler design of claim 1, which consists essentially of a foamed polyurethane insert.
 3. The flangeway filler design of claim 2, which has a substantially planar uppermost surface and a beveled bottom with two or more support legs surrounding a triangular shaped, central gap region.
 4. A railroad flangeway filler strip for a section of pre-existing embedded railroad track, said filler strip having a substantially planar uppermost surface made from foamed urethane and a hard urethane base beneath the substantially planar uppermost surface.
 5. The railroad flangeway filler strip of claim 4 wherein the hard urethane base includes at least one rounded lower corner/edge.
 6. The railroad flangeway filler strip of claim 5, which has one or more mounting holes extending therethrough.
 7. The railroad flangeway filler strip of claim 9 wherein said mounting holes are angled towards the rounded lower corner/edge.
 8. A railroad flangeway filler design for a section of new embedded railroad track, said design consisting essentially of a foamed polyurethane insert adjacent a section of rail and a section of steel flangeway.
 9. The flangeway filler design of claim 8, which includes a substantially hook-shaped joinder element for interacting with one or more downward extensions from the section of steel flangeway.
 10. The flangeway filler design of claim 9, which is substantially shaped like a reverse J.
 11. The flangeway filler design of claim 9, which has an enlarged section closest the section of rail, a centralized gap region with a connecting base to the enlarged section, and a thin hook leg region extending upward from a distal end of the connecting base opposite the enlarged section.
 12. The flangeway filler design of claim 12 wherein the hook leg region does not extend upwardly as high as the enlarged section.
 13. A method for making a flangeway filler for a freight railroad and grade crossing, said method comprising: (a) forming molded foam urethane inserts in a plurality of sizes and cross-sectional shapes; (b) measuring the freight railroad and grade crossing for a width and length of molded foam urethane insert needed; (c) determining cross-sectional shape needed for inserting into the freight railroad and grade crossing; (d) cutting the molded foam urethane insert having the proper cross-sectional shape for inserting into the freight railroad and grade crossing; and (e) anchoring the cut, molded foam urethane insert into the freight railroad and grade crossing to make the flangeway filler.
 14. The method of claim 13, which further includes, prior to step (e): forming a base for the flangeway filler, said base being made from steel.
 15. The method of claim 14 wherein the steel base is coated with hard urethane prior to inserting into the freight railroad and grade crossing.
 16. The method of claim 13, which further includes, prior to step (b): storing the various plurality of sizes and cross-sectional shapes of molded foam urethane inserts in elongated lengths.
 17. The method of claim 13, which further includes, prior to step (b): storing the various plurality of sizes and cross-sectional shapes of molded foam urethane inserts onto spools.
 18. The method of claim 13, which further includes, prior to step (b): providing the molded foam urethane inserts with a plurality of spaced apart mounting holes.
 19. The method of claim 13, which further includes, prior to step (e): (i) drilling a plurality of spaced apart mounting holes into the cut molded foam urethane inserts; and (ii) securing the molded foam urethane inserts into the freight railroad and grade crossing through one or more of the plurality of spaced apart, drilled mounting holes. 